Kaneka Core-Shell Toughening Systems for …

1 Douglas J. Texas Corp2 Northpoint DriveSuite 200 Houston, TX CoreKaneka core -- shell Toughening shell Toughening Systems for Thermosetting ResinsSystems for Thermosetting ResinsWhat is CoreWhat is core -- shell Rubber (CSR) ? shell Rubber (CSR) ?2-Layer CSRCo-Polymer II designedto be compatible withthermosetting is the I designedfor impact is the is CoreWhat is core -- shell Rubber (CSR) ? shell Rubber (CSR) ?2-Layer CSR100nmApplications of CSR?Applications of CSR? Thermoplastic resins Thermosetting resins Systems Electrical Castings- Coatings- Copper-Clad LaminatesCore shell Rubber Advantages: core shell Rubber Advantages: Outstanding Toughness Improvement:- Fracture Toughness-T-Peel Strength- Lap-Shear Strength No Depression of Tg. Wide Cure Window. Consistent Morphology. Low Ionic and Surfactant Content. Extremely Stable. Compatible / synergistic with Secondary Tougheners. Nano-size particles do not filter.

2 Composite parts tend to be very does CSR toughen resins?How does CSR toughen resins? core polymer cavitates on impact dissipating energy. Reduced damage area Small, evenly dispersed particlesact as a crack terminator. core polymer relieves inherent stress generated during & peelstrengthimprovementDimensional stability& microcrack resistanceNote: Optimization of particle size and inter-particle distance (volumetric particle concentration) is critical to achieving the best performanceCSR Manufacturing ProcessEpoxySolid CSRCan only be broken up to 1500 nm minimum with wide particle size distributionKANEKA CSR ProcessEpoxy/CSRKane Ace MXAgglomeration /DryingLatexMX ProcessNarrow range of 100 nm particlesBasic Properties of MX systemCore shell Rubber particles are homogeneously dispersed in epoxy resin with long term stabilityCore shell Rubber particles are homogeneously dispersed in epoxy resin with long term stabilityConventional Solid CSR(10 wt%) in epoxyNew MX CSR(25 wt%) in epoxyAppearance - Cured system Transparent TEM observation - Cured systemComparison of Kane Ace MX CSR versus Powder CSR1 mMX CSRP owder CSRA ppearance of MX and CTBN (in DGEBA epoxy )No toughenerCSR phrCTBN phrWhat is Kane Ace MX:What is Kane Ace MX.

3 Kane Ace MX are concentrates comprised typically of 25% by weight of CSR dispersed in various thermosetting resins. The liquids are easily poured after heating and the individual CSR domains remain uniformly dispersed during storage and formulating. Kane Ace MX Products:Kane Ace MX Products:GradeCSR Type / LoadingCarrier ResinMX 124St-Bd 25%Liquid Bis A epoxy (lowest viscosity)MX 125St-Bd 25%Liquid Bis A epoxy MX 133St-Bd 25% Liquid Bis F epoxy (lower viscosity)MX 135St-Bd 25%Low crystallizing liquid Bis F epoxyMX 136p-Butadiene 25%Liquid Bis F epoxy (lower viscosity)MX 153 p-Butadiene 33%Liquid Bis A epoxyMX 156p-Butadiene 25%Liquid Bis A epoxyMX 210St-Bd 25%Epoxidized Phenol NovolakMX 227*St-Bd 25%Epoxidized BPA NovolakMX 338St-Bd 25%Brominated Di-functional epoxyMX 392St-Bd 25% Brominated Multifunctional epoxyMX 416p-Butadiene 25% Multifunctional epoxy Resin (TGMDA)MX 451St-Bd 25%Multifunctional epoxy Resin (TGPAP)MX 554St-Bd 25%Cyclo-Aliphatic epoxy (MX 601*St-Bd 25%Resole NovolakMX 615St-Bd 25%Di-allyl BPA (for BMI)MX 660 Siloxane 25%Di-allyl BPA (for BMI)MX 715St-Bd 25%Polypropylene Glycol carrier (mw 400)MX 717St-Bd 25%Polypropylene Glycol carrier (mw 1000))

4 MX 719St-Bd 25%Polypropylene Glycol carrier (mw 2000)MX 960 Siloxane 25% Liquid Bis A epoxy *Developmental grades not yet available in commercial quantitiesExample for Comparative TrialExample for Comparative TrialPart A:70 parts liquid Bis A resin52 parts liquid Bis A resin20 parts epoxy resin B20 parts epoxy resin B10 parts reactive diluent10 parts reactive diluent24 parts MX 125 Part B:30 parts Part B30 parts Part BMix Ratio Part A to B:100/30106:30 core shell Concentration:0% SystemMX ToughenedBasic Properties of MX systemMX 125 Viscosity as a Function of Concentration020,00040,00060,00080,00010 0,000120,000140,000051015202530 CSR concentration (wt%)Viscosity (cps)25C50 CWorkingRangeKaneka Kane Ace MX Adhesive ApplicationsT-Peel Strength Kane Ace MXASTM D1876T-Peel Strength of DGEBA epoxy /MX 120 System05101520253035T-peel Strength / pliC SR 0% C SR 5% C SR 10%Lap-Shear Strength OF Kane Ace MXAdhesive layerASTM D10020100020003000400050006000 Lap Shear PSI0 % Control5 % CSR10 % CSRLap-shear Strength of DGEBA epoxy /MX 120T-peel Strength of MX 120 vs.

5 CTBN in DGEBA EpoxyC ontrol5%10%CTBNCSR M aster-batch05101520253035T-peelStrength/ pliComparison of CSR and CTBNC omparison of CSR and CTBNLap-shear Strength of MX 120 vs. CTBN in DGEBA EpoxyControl5%10%CTBNCSR M aster-batch0100020003000400050006000 Lap-shearStrength/psiKaneka Kane Ace MX Composite ApplicationsTypes of Fractures Depending on the stress field in the vicinity of the crack tip, three principle fracture modes are possible: Mode I, Mode II, and Mode III. Mode I bending is tensile, Mode II is shear, Mode III is tearingToughening Effect of epoxy / Kane Ace MX SystemToughening Effect of epoxy / Kane Ace MX SystemThree-Point Bendingforcespecimen: 6cm x x : depth by blade-tappinghead speed: 1 5045 CastingASTM 5528 ReinforcedFracture Toughness of DGEBA epoxy /MX MPam1/ 2 CSR 0%CSR 10%DDSpiperidineFracture Toughness of DGEBA epoxy /MX 12005001000150020002500G1c/Jm 2 CSR 0% CSR 10%DDSpiperidineComparison of CSR and CTBNC omparison of CSR and CTBNF racture Toughness and Glass Transition Temperature of MX 120 vs.

6 CTBN in DGEBA Epoxy0100200300400500600control CSR Master- batch CTBN J/m2050100150200250Tg CTgKaneka Kane Ace MX Coatings ApplicationsKaneka Kane Ace MX Vinyl Ester (85/15) (J/m2)K1C(MPa m1/2)Fracture Toughness of Vinylester / MX153 systemVinylester: Reichhold 9800-05A, Casting: 50C/17hr-120/2hrKaneka Kane Ace MX Copper-Clad Laminates ApplicationsLead-Free Data Sheets IPC-4101B: Slash Sheet #99101121124126129Tg min150110110150170170Tg maxTd min325310310325340340 FillersyesyesnonoyesnoFlame retardantRoHS BR RoHS BR RoHS BR RoHS BR RoHS BR RoHS BRCuring AgentN/AN/AN/AN/AN/AN/AFlammabilityV-0V- 0V-0V-0V-0V-0Z-Axis alpha 1 max606060606060Z-Axis alpha 2 max300300300300300300% MOTAABUSAABUSAABUSAABUS130130 Amendment 2 THE REACTION OF DICY WITH epoxy RESIN:BASE MATERIAL WORKSHOP(DICY)Phenol Novolak Resinspopular curing agentsfor lead-free FR-4 EFFECT OF CROSS LINK DENSITY ON LAMINATE PROPERTIES:BASE MATERIAL WORKSHOPTG/TdPEELSTRENGTHINTERLAMADHESIO NCHEMICALRESISTANCEFRACTURETOUGHNESSTHER MALRESISTANCEZ-AXISCTECROSS LINKDENSITY OFSYSTEMGoodGoodGoodGoodBadBadBadPad CrateringPad CrateringLife ScienceProductsSynthetic fiberElectronic ProductsFoodstuffs ProductsExpandable ProductsCo Q10 Functional PlasticsGlobal Revenue: $ billion 2006 #1 Producer of CSR Toughening Agents Worldwide Kaneka Corporation Today Kaneka is a world leader in the creation of innovative technologies in areas such as polymers, construction materials, and pharmaceuticals.

7 Kaneka is a global organization with production facilities on four continents and approximately 7000 employees. Revenue for our latest fiscal year (ended March 06) is estimated worldwide at approximately $ Global Manufacturing Kaneka currently manufactures Modifiers at four sites around the world. These include: Kaneka JapanAsiaTakasago, JapanKaneka TexasUSAP asadena, TexasKaneka BelgiumEuropeOevel, BelgiumKaneka MalaysiaAsiaKuantan, Malaysia These four sites provide Kaneka with an annual capacity of modifiers of approximately 400 million pounds. Kaneka Texas Corporation A wholly owned subsidiary opened in 1983, Kaneka Texas (KTC) is responsible for marketing several Kaneka product lines throughout the Americas. Business operating at KTC include: 1.) Polymer Modifiers (Kane Ace) 2.) CPVC Resins (Kanevinyl) 3.) Foamed Olefins Resins (Eperan, Eperan PP) 4.) Modified Silicone for Sealants (MS Polymer) 5.

8 Polyimide Film (Apical) 6.) Nutrients (CoQ10)